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Posted by Bill Homer[Email] (more from Bill Homer) on Mon, 13 May 2019 16:57:10
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I recently had the clutch replaced on my 1994 9000 Aero and it was shifting wonderfully for a few days - then it wasn't, car is hard to get into fourth gear. I checked the alignment using two screwdrivers in the holes procedure, everything was fine. After poking around under the hood, I found that the selector shaft joint at the taper pin is quite loose, can be wiggled with finger pressure. The nut was tightened by the transmission shop to the point where it was just spinning on the taper pin past the threaded area. I removed the nut, inserted a couple of washers and a new nyloc nut and tightened it as much as I dared to for an M5 bolt and an 8mm nut - everyone knows that it is a pain to remove this pin if it breaks. Despite tightening the nut pretty firmly, the joint never really got tight, and I'm afraid to tighten it any more.

Is there a good solution for this? My ideas so far:
1. Is a new taper pin going to help at all (assuming that I can get the old one out using a C-clamp).
2. Would removing or drilling out the taper pin and using a larger diameter bolt help any? It appears that there is just barely enough room to get my small air drill in the area.
3. Maybe sticking in a shim of some sort between the inner and outer parts?

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